PFERD Tools for Use on Aluminium Tools for Use on Aluminium Contents

PFERD produces a comprehensive tool range for the most diverse aluminium machining and finishing tasks. All of these products have been purpose-developed for their respective application and are proven in practice.

In the present issue of PFERD-PRAXIS we have summarized our experience of many years, including the very latest know-how, on the specific machining and performance behaviour of tools for use on aluminium and its diverse alloys.

Aluminium Tools for Use on Aluminium from PFERD Catalogues 201 – 209...... 25 A material with a future ...... 3 On pages 26 – 36 we describe the special properties of More than 1,000 alloys ...... 4 individual groups of tools which are particularly well suited for use on aluminium, adhering to the structure of our Properties of aluminium ...... 5 PFERD Catalogues 201 – 209.

Machinability groups...... 6 Files...... Catalogue. 201 + 205. 26 Aluminium machining recommendations . . . . . 7 Rotary cutters...... Catalogue. 202. . . . . 27

Important safety instructions...... 8 Hole saws and hole cutters. . . . . Catalogue. 202. . . . . 28

Aluminium working processes...... 9 Mounted points. . . . . Catalogue. 203. . . . . 29 On pages 10 – 24 we show you which PFERD tools are best Grinding and suited for solving the various application needs in working with aluminium. polishing tools ...... Catalogue. 204. . 30 – 31

Abrasive cut-off Abrasive cut-off wheels. . . Catalogue 206. . . . . 32 and cutout work...... 10. – 11 Reinforced Deburring...... 12. – 13 grinding wheels. . . . . Catalogue. 206. . . . . 33

Preparation for welding - POLIFAN®- joint preparation ...... 14. – 15 flap wheels...... Catalogue. 206. . . . . 34

Preparation for welding - Industrial surface machining ...... 16. – 17 power brushes...... Catalogue. 208. . . . . 35

Weld dressing...... 18. – 19 Power tools...... Catalogue. 209. . . . . 36

Fine-grinding and finishing...... 20 – 21

Texturing...... 22 – 23

Polishing...... 24

2 Aluminium A material with a future

The use of aluminium and its alloys is growing, and so are metalworking applications involving this material – why?

Aluminium, at about 8%, is the most abundant element in the earth’s crust after oxygen and silicon. Given the material properties of aluminium and its alloys, i.e., n extreme durability n low weight n corrosion resistance n recyclability aluminium materials have become progressively more widespread in recent years.

The development of ever more lightweight parts which must nevertheless meet unchanged strength requirements has given rise to an ever-growing use of aluminium alloys. The latter can be formed into virtually any shape using a variety of industrially available processes (casting, rolling, extruding), which opens up a wealth of options to the industrial user or processor of aluminium alloys. At the level of joining technology, one focus of development lies on adapting common metal-joining processes so as to make them suitable for use with aluminium alloys.

In many segments and branches of industry, materials have to meet exacting demands regarding surface quality, environmental performance and safety. Ad- vanced transport systems are no longer conceivable without the use of lightweight aluminium components. In addition, aluminium as a material group perfectly satis- fies today’s increasingly stringent environmental requirements concerning product recyclability.

Our goal is to provide you with optimum results and unsurpassed cost efficiency in your aluminium machining and finishing work

By now, nearly all welding processes for joining aluminium and its alloys have become available on an industrial scale, reflecting the special properties of this material.

Special aluminium alloys have become the material of choice in a wide range of applications from housings, vehicles, tank construction, mechanical engineering to doors, windows, foundations, heat exchangers and aerospace components.

An increasingly numerous user community is aiming for optimum results and maximum cost-efficiency in aluminium machining or processing. At PFERD, the development of new aluminium-working tools has therefore been a high priority for decades.

3 Aluminium More than 1,000 alloys

Is all aluminium the same?

Unsurprisingly, no. The catch-all term “aluminium” refers to a group of alloys which share aluminium as their main constituent - a broad range of metallic compounds based on pure aluminium and one or more additional elements.

Over 1,000 aluminium alloys exist today. They all have been purpose-developed to improve the properties of the base metal.

What do the various aluminium alloys have in common? n They all contain at least 60% pure aluminium. n Their specific gravity is much lower than that of steel. n They are usually corrosion resistant. n They have an excellent electrical and thermal conductivity.

Which distinctions are made between the various aluminium alloys?

n Wrought alloys and associated weld filler materials (sheet metal, strip, sections, rods, tubes, forgings)

n Casting alloys and associated weld filler materials (sand/gravity die casting, precision casting)

In addition, one must differentiate between

n Heat treatable and

n Non-heat treatable alloys .

In heat-treatable material, the state of the alloy is of key importance for its machining properties. By means of heat treatment processes such as age hardening or soft annealing, in combination with the use of different mixing ratios, entirely different material properties can be achieved. The following characteristics can all be modified:

n Strength

n Density

n Corrosion resistance

n Conductivity

n Machinability

n Visual appearance of the bare metal

4 Aluminium Properties of aluminium

Which factors influence aluminium machining?

The greatest challenge with most aluminium alloys lies in their machinability properties. Depending on the alloy and its heat treatment condition, the material may prove soft and ductile or hard and brittle in the machining process. Hardness is an important alloy classification criterion. A less-than-optimum geometry of the cutting faces will result in edge build-up, an effect commonly responsible for tool loading problems. It may also dramatically reduce tool life.

Given the high oxygen affinity of aluminium, a dense layer of oxide will form on its surface upon exposure to air and/or water. This oxide protects the underlying metal from corrosion, albeit not fully.

What should be borne in mind with regard to mechanical machining of surfaces?

The material’s corrosion behaviour is influenced strongly by its surface properties and the way these are changed by grinding, polishing or brushing.

While every surface smoothing operation will enhance the corrosion resistance of aluminium, roughing jobs will generally diminish it. Particles of foreign matter impressed into the surface will likewise impair the material’s corrosion resistance.

Mechanical surface machining of pure aluminium or alloys having a Brinell hardness of less than 40 HB requires caution and experience.

The pressure exercised during grinding and polishing must be adapted to the material’s specific hardness since soft alloys tend to become gummy. In addition, grinding dust or abrasive particles may be impressed into the surface, destroying the enhanced visual appearance one intends to produce. Photo: Otto Fuchs

Many new aluminium-based alloys will still be developed in the future, given that the properties of this material make it indispensable in our modern world. Aluminium has therefore also been called the ‘metal of the new century’.

5 Aluminium Machinability groups SOFT, TOUGH, HARD

For optimum machining results on aluminium and its diverse alloys according to EN standards, PFERD distinguishes three machinability groups (Soft, tough, hard). Each of these represents a different Brinell hardness range. On the following pages, suitable PFERD tools are allocated to each of these groups. Photo: Otto Fuchs Photo: Otto Fuchs MACHINABILITY GROUP MACHINABILITY GROUP MACHINABILITY GROUP HB SOFT TOUGH harD

n Non heat-treatable wrought alloys EN AW 1000 – 1999 EN AW 2000 – 2999 15 EN AW 3000 – 3999 EN AW 5000 – 5999 n Heat-treatable alloys in a soft stage EN AW 6000 – 6999 EN AW 7000 – 7999 n Welding filler materials 40 n n Non heat-treatable Wrought alloys with low aluminium casting alloys silicon contents EN AC 5000 – 5999 EN AW 4000 – 4999 n EN AB 5000 – 5999 Heat treatable wrought alloys n Heat-treatable aluminium EN AW 6000 – 6999 casting alloys in a soft stage EN AW 7000 – 7999 60 EN AC 4000 – 4999 EN AB 4000 – 4999 n Welding filler materials n Heat-treated aluminium casting alloys with silicon contents < 12% EN AC 4000 – 4999 100 EN AB 4000 – 4999 n Non heat-treated aluminium casting alloys with silicon content < 12% EN AC 4000 – 4999 EN AB 4000 – 4999

n Heat treated wrought 120 alloys with chipbreaking properties

n Aluminium casting alloys with 130 silicon content > 12% (responsible for high tool wear n Self-hardening aluminium casting alloys without silicon EN AC 2000 – 2999 EN AC 7000 – 7999 EN AB 2000 – 2999 EN AB 7000 – 7999 Index n Heat-treated aluminium 140 HB = Brinell hardness casting alloys without silicon EN AC 2000 – 2999 EN = European Standard EN AC 7000 – 7999 AB = Alloyed EN AB 2000 – 2999 aluminium ingots EN AB 7000 – 7999 n Weld filler materials AC = Aluminium castings 150 n Heat-treated wrought alloys AW = Wrought EN AW 6000 – 6999 aluminium materials EN AW 7000 – 7999 n Weld filler materials

6 Aluminium Machining recommendations

Which recommendations must be observed in aluminium machining?

Cutting speed (r .p .m .) n For an optimum surface finish, the cutting speed needs to be adapted to the machining process as well as to the alloy and its heat treatment state. Observe the r.p.m. recommendations on the following pages.

Contact pressure n Local overheating due to excessive grinding pressure may cause microstructural alterations in the affected aluminium areas. As a result, the material’s visual appearance may be impaired after subsequent electrolytic surface treatment. n Avoid high contact pressures to prevent abraded particles and abrasive material from getting impressed into the workpiece surface. n Compared with conventional steel materials, aluminium alloys must be ground with a reduced contact pressure. This is the only way to avoid intense heating of the workpiece and to achieve a good surface finish.

Cooling n The use of grinding oils and grinding grease prevents excessive temperature build-up and helps to achieve good cooling, especially with finer-grained abrasives.

Corrosion n To avoid contact corrosion due to the presence of abraded material on the machined surface, the tools employed (e.g., brushes) must not consist of copper alloys or steel. n The use of abrasive or polishing wheels or brushes which have previously been used on other metals is likewise to be avoided. A strict separation of tools is absolutely necessary.

7 Aluminium Important Safety Instructions

Safety notes of the German Association of Workmen’s Compensation Insurers

In its Rules for Safety and Health at Work (BGR 109), the German Association of Workmen’s Compensation Insurers defines practices and precautions aimed at preventing hazards such as dust fires and dust explosions during grinding, brushing and polishing.

The publication issued by the Association of Workmen’s Compensation Insurers provides information on aspects such as, e.g.:

n design of metalworking machines, associated equipment, workshops and storage rooms; n extraction, conveyance, collection, storage and transport of dusts and associated sludges; n machining and separation of different materials (aluminium and sparking materials such as steel); n avoidance of ignition sources; n extinguishing systems and fire fighting; n cleaning and maintenance; n personal protective equipment and workwear; n operating instructions, training and equipment inspection; n hazard assessment, explosion protection document, cleaning and maintenance schedules; n regulations of the German Association of Workmen’s Compensation Insurers, rules, principles and information, as wells as laws, ordinances and standards.

Safety recommendations PRECAUTIONS AGAINST LIKELY HAZARDS SAFETY RECOMMENDATIONS FOR THE USE OF ABRASIVE PRODUCTS Noise FEDERATION·OF·EUROPEAN Please observe FEPA safety recommendations as well as the pictograms. PRODUCERS·OF·ABRASIVES • Ear protection complying with EN352 is recommended for all applications where the workpiece or machine is hand-held, irrespective of the noise level. PASS ON THIS LEAFLET TO THOSE USING THE ABRASIVE PRODUCT The recommendations contained in this leaflet shoult be followed by • Ensure that the correct abrasive product is selected. An unsuitable product can produce all users of abrasive products in the interests of their personal safety. excessive noise.

Vibration Not approved for GENERAL PRINCIPLES OF SAFETY = Wear safety glasses! = • Processes where the workpiece or machine is hand-held can cause vibration injury. wet grinding! • Action needs to be taken if tingling, pins and needles or numbness is experienced after 10 Abrasive products improperly used can be very dangerous. minutes continuous use of the abrasive product. • Always follow the instructions provided by the abrasive product and machine • The effects of vibration are more pronounced in cold conditions so keep the hands warm and supplier. exercise hands and fingers regularly. Use modern equipment with low vibration levels. • Ensure that the abrasive product is suitable for its intended use. Examine all abrasive products Not approved for • Maintain all equipment in good condition and stop the machine and have it checked if for damage or defects before mounting. = Wear protective gloves! = excessive vibration occurs. • Follow the correct procedures for handling and storage of abrasive products. side grinding! • Use good quality abrasive products and keep them in good condition during their life. Be aware of the hazards likely during the use of abrasive products and observe the • Maintain mounting flanges and back-up pads in good condition and replace if worn or recommended precautions to be taken: distorted. • Bodily contact with the abrasive product at operating speed. • Do not grip the workpiece or machine too tightly and do not exert excessive pressure on the • Injury resulting from product breakage during use. abrasive product. Do not use • Grinding debris, sparks, fumes and dust generated by the grinding process. = Use ear protection! = • Avoid continuous use of the abrasive product. • Noise. damaged wheels! • Use the correct product. An unsuitable product can produce excessive vibration. • Vibration. • Don’t ignore the physical symptoms of vibration - seek medical advice. Use only abrasive products conforming to the highest standards of safety. These products will bear the relevant EN standard number and/or the inscription “oSa”. Disposal of abrasives • EN12413 for Bonded Abrasives. Not approved for • Used or defective abrasives should be disposed in accordance with local or national regulations. • EN13236 for Superabrasives. • EN13743 for Specific Coated Abrasives (vulcanised fibre discs, flap wheels, flap • Further information can be obtained from material safety data sheets provided by the supplier. = Wear a dust mask! = freehand and manually guided discs and spindle-mounted flap wheels). • Be aware that the abrasive product may be contaminated with material from the workpiece or grinding! process after use. Never use a machine that is not in good working order or one with defective parts. • Disposed abrasive products should be damaged to prevent them from being taken from waste Employers should carry out a risk assessment on all individual abrasive processes to determine the skips and reused. appropriate protective measures necessary. They should ensure that their employees are suitably trained to carry out their duties. Use only with National Association Important notice Leaflet supplied and endorsed by Every effort has been made to = ensure that all informatinon August Rüggeberg GmbH This leaflet is only intended to provide basic safety recommendations. We strongly recommend supplied in this leaflet is accurate & Co. KG that or more detailed information on the safe use of abrasive products, comprehensive Safety backing pad! PFERD-Werkzeuge Tel.: 0228 / 635587 and up to date. We can not Codes are available from FEPA or your National Trade Association: accept, however, responsibility Hauptstraße 13 Fax: 0228 / 635399 51709 Marienheide for any error or omission, nor for National Association Tel. (0 22 64) 90 • FEPA Safety Code for Bonded Abrasives and Precision Superabrasives. any consequential loss or damage Fax (0 22 64) 94 00 www.fepa-abrasives.org so arising (E & OE). • FEPA Safety Code for Superabrasives for Stone and Construction. © FEPA 2004 Observe safety recommen- Issue 1 – Nov 2004 www.pferd.com · [email protected] • FEPA Safety Code for Coated Abrasives. = dations FEPA safety recommendations are available for download at www.pferd.com.

8 Aluminium Machining Processes

Page Abrasive cut-off and cutout work 10 – 11

Deburring 12 – 13

Preparation for welding - joint preparation 14 – 15

Preparation for welding - surface machining 16 – 17

Weld dressing 18 – 19

Fine and finishing work 20 – 21

Texturing 22 – 23

Polishing 24

9 Abrasive Cut-Off and Cutout Work

Machining tasks: n Cutting off sections, sheet metal, risers and pipes n Producing cutouts in tanks and switchgear cabinets, e.g., for con- nections and pipe penetrations n Producing cutouts and notches in sectional material and thin-walled parts

Machinability group SOFT HSS hole saws

T/C hole cutters

Abrasive cut-off wheels 30-76 mm A 60 P SG 15 – 60 HB

Machinability group TOUGH HSS hole saws

T/C hole cutters

Abrasive cut-off wheels 30-76 mm A 60 P SG 40 – 150 HB

Machinability group harD T/C hole cutters

Abrasive cut-off wheels 30-76 mm A 60 P SG 100 – 150 HB Photo: Otto Fuchs

10 Abrasive Cut-Off and Cutout Work

Machinability group SOFT Abrasive cut-off wheels A 24/30 N SG-Alu 15 – 60 HB

Machinability group TOUGH Abrasive cut-off wheels A 24/30 N SG-Alu

Abrasive cut-off wheels A 60 R SG-INOX 40 – 150 HB

Machinability group harD Abrasive cut-off wheels Abrasive cut-off wheels A 24/30 N SG-Alu C 36 K SG-CHOP

Abrasive cut-off wheels Abrasive cut-off wheels A 60 R SG-INOX C 36 L SG-TABLE

Abrasive cut-off wheels Abrasive cut-off wheels C 30 R SG C 24 O SG-UNI 100 – 150 HB

11 Deburring

Machining tasks:

n Deburring of edges, cutouts and contours n Chamfering n Removing flash from castings

Machinability group Poliflex®- Abrasive spiral T/C burr SOFT mounted fine- bands GSB Z-ALU grinding point TX Z-COOL, CO-COOL

T/C burr COMBIDISC®- Grinding oils Z-ALU + abrasive discs 412 ALU coating A-COOL, SiC

Fan grinders POLINOX®- HSS rotary cutter Z-COOL, SiC, ring wheels Z-ALU CO-COOL PNER

15 – 60 HB Wheel brushes, Mounted points Flap wheels mounted, individual Hardness F-Alu filament type RBU SiC/INOX Photo: Otto Fuchs Wheel brushes, with Mounted points POLISTAR arbor hole, indi- Hardness L vidual filament type RBU SiC/INOX

Machinability group Poliflex®- Abrasive spiral T/C burr TOUGH mounted fine- bands GSB Z-ALU grinding point TX Z-COOL, CO-COOL

T/C burr COMBIDISC®- Grinding oils Z-ALU + abrasive discs 412 ALU coating A-COOL, SiC

Fan grinders POLINOX®- HSS rotary cutter Z-COOL, SiC, ring wheels Z-ALU CO-COOL PNER Wheel brushes, 40 – 150 HB Mounted points POLISTAR mounted, individual Hardness F-Alu filament type RBU SiC/INOX Wheel brushes, with Mounted points arbor hole, indi- Hardness L vidual filament type RBU SiC/INOX

Machinability group Poliflex®- Abrasive spiral T/C burr HARD mounted fine- bands GSB Z-ALU grinding point TX Z-COOL, CO-COOL

T/C burr COMBIDISC®- Grinding oils Z-ALU + abrasive discs 412 ALU coating A-COOL, SiC

Fan grinders POLINOX®- HM rotary cutter Z-COOL, SiC, ring wheels Z-3 CO-COOL PNER Wheel brushes, 100 – 150 HB Mounted points POLISTAR mounted, individual Hardness F-Alu filament type RBU SiC/INOX Photo: Otto Fuchs Wheel brushes, with Mounted points arbor hole, indi- Hardness M vidual filament type RBU SiC/INOX

12 Deburring

Machining tasks: n Deburring of edges, cutouts and contours n Chamfering n Removing flash from castings

Machinability group Fibre discs POLIFAN®-flap Short belts T/C burrs SOFT A-COOL, discs A-COOL, Z-ALU Rasps CO-COOL SG-A-COOL CO-COOL Z-ALU +coating

COMBICLICK® Flaring cup HSS rotary Files for soft A-COOL, brushes with Long belts cutter metal CO-COOL threaded hole Z-ALU individual fila- Wheel brushes ment with arbor hole, PLUS® file Grinding oils type, KBU INOX Grinding oils individual Machinist’s file - 412 ALU filament type, Cut 1 Flaring cup brush RBU SiC/INOX

with threaded 15 – 60 HB Reinforced Wheel brushes, hole, knotted, grinding wheels mounted, Milled tooth file KBG INOX individual A 24 N SG-ALU filament type, Wheel brushes RBU SiC/INOX Reinforced unmounted Disc brushes, Interior brushes, grinding wheels knotted, RBG CT individual threaded C 24 Q SG INOX filament type, IBU SiC/INOX DBU SiC Machinability group Fibre discs POLIFAN®-flap Short belts T/C burrs TOUGH A-COOL, discs A-COOL, Z-ALU Rasps CO-COOL SG-A-COOL CO-COOL Z-ALU +coating

COMBICLICK® Flaring cup HSS rotary Files for soft A-COOL, brushes with Long belts cutter metal CO-COOL threaded hole Z-ALU individual filament type, Wheel brushes PLUS® file Grinding oils with arbor hole, KBU INOX Grinding oils Machinist’s file - 412 ALU individual Flaring cup brush filament type, Cut 1 RBU SiC/INOX with threaded

Reinforced 40 – 150 HB hole, knotted, Wheel brushes, grinding wheels mounted, Milled tooth file KBG INOX A 24 N SG-ALU individual Wheel brushes filament type, Reinforced unmounted RBU SiC/INOX Interior brushes, Disc brushes, grinding wheels knotted, RBG CT individual threaded C 24 Q SG INOX filament type, IBU SiC/INOX DBU SiC

Machinability group Fibre discs POLIFAN®-flap Short belts T/C burr HARD A-COOL, discs A-COOL, Rasps Z-ALU CO-COOL SG-A-COOL CO-COOL

COMBICLICK® Flaring cup T/C burr Files for soft A-COOL, brushes with Long belts Z-ALU + metal CO-COOL threaded hole coating individual Wheel brushes filament type, PLUS® file Grinding oils with arbor hole, KBU INOX Grinding oils individual fila- Machinist’s file - 412 ALU ment type, Cut 1 Flaring cup brush RBU SiC/INOX with threaded Reinforced Wheel brushes, hole, knotted, mounted, 100 – 150 HB grinding wheels Milled tooth file KBG INOX individual A 24 N SG-ALU filament type, Wheel brushes RBU mSiC/INOX Reinforced unmounted Disc brushes, Interior brushes, grinding wheels knotted, RBG CT individual threaded C 24 Q SG INOX filament type, IBU SiC/INOX DBU SiC

13 Preparation for Welding – Joint Preparation

Machining tasks: n Chamfering

n V-seam preparation n Grinding out shrink holes n Preparation of repair welds

Machinability group Abrasive spiral T/C burr Grinding oils SOFT bands GSB Z-ALU 412 ALU Z-COOL, CO-COOL

T/C burr Z-ALU + POLIROLL® coating

HSS rotary COMBIDISC®- cutter abrasive discs Z-ALU A-COOL, CO-COOL SiC 15 – 60 HB Mounted points ATADISC® Hardness F-Alu abrasive discs

Mounted points Hardness L

Machinability group TOUGH T/C burr Mounted points ATADISC® Z-ALU Hardness L abrasive discs

T/C burr Abrasive spiral Grinding oils Z-ALU + bands GSB 412 ALU coating Z-COOL, CO-COOL

T/C burr POLIROLL® Z-ALU PLUS

COMBIDISC®-

40 – 150 HB HSS rotary cutter abrasive discs Z-ALU A-COOL, CO-COOL SiC Mounted points Hardness F-Alu

Machinability group HARD T/C burr Mounted points ATADISC® Z-ALU Hardness M abrasive discs

T/C burr Abrasive spiral Grinding oils Z-ALU + bands GSB 412 ALU coating Z-COOL, CO-COOL

T/C burr POLIROLL® Z-ALU PLUS

COMBIDISC®- 100 – 150 HB T/C burr abrasive discs Z-3P A-COOL, CO-COOL SiC Mounted points Hardness F-Alu

14 Preparation for Welding – Joint Preparation

Machining tasks: n Chamfering n V-seam preparation n Grinding out shrink holes n Preparation of repair welds

Machinability group Fibre discs Short belts SOFT Rasps A-COOL, CO-COOL A-COOL, CO-COOL

COMBICLICK® Long belts Files for soft metal A-COOL, CO-COOL

Grinding oils Grinding oils PLUS® file 412 ALU 412 ALU 15 – 60 HB Reinforced grinding wheels Machinist’s file - Cut 1 A 24 N SG-ALU

POLIFAN® flap discs Milled tooth file SG-A-COOL

Machinability group Fibre discs Short belts TOUGH Files for soft metal A-COOL, CO-COOL A-COOL, CO-COOL

COMBICLICK® Long belts PLUS® file A-COOL, CO-COOL

Grinding oils Grinding oils Machinist’s file - Cut 1 412 ALU 412 ALU

Reinforced grinding wheels 40 – 150 HB Milled tooth file A 24 N SG-ALU

POLIFAN® flap discs SG-A-COOL

Machinability group Fibre discs Short belts HARD Files for soft metal A-COOL, CO-COOL A-COOL, CO-COOL

COMBICLICK® Long belts PLUS® file A-COOL, CO-COOL

Grinding oils Grinding oils Machinist’s file - Cut 1 412 ALU 412 ALU

Reinforced grinding wheels 100 – 150 HB Milled tooth file A 24 N SG-ALU

POLIFAN® flap discs Diamond files SG-A-COOL

15 Preparation for Welding – Surface Machining

Machining tasks: n Removing oxide skin

n Cleaning n Removal of impurities without sig- nificant dimensional changes

Machinability group Wheel brushes, with ® SOFT COMBIDISC - arbor hole, indi- non-woven discs vidual filament type, RBU SiC/INOX Poliflex® fine-grinding tools PUR, GR

POLINOX®- mounted points PNZ/PNL/PNR/PNG

15 – 60 HB POLINOX®- abrasive wheels PNZ/PNL/PNR/PNG

Wheel brushes, mounted, individual filament type,

Machinability group Wheel brushes, with ® TOUGH COMBIDISC - arbor hole, indi- non-woven discs vidual filament type, RBU SiC/INOX Poliflex® fine-grinding tools GR / TX

POLINOX®- mounted points PNZ/PNL/PNR/PNG

40 – 150 HB POLINOX - abrasive wheels PNZ/PNL/PNR/PNG

Wheel brushes, mounted, individual filament type,

Machinability group Wheel brushes, with ® harD COMBIDISC - arbor hole, indi- non-woven discs vidual filament type, RBU SiC/INOX Poliflex® fine-grinding tools GR / TX

POLINOX®- mounted points PNZ/PNL/PNR/PNG

POLINOX®- 100 – 150 HB abrasive wheels PNZ/PNL/PNR/PNG Photo: Otto Fuchs Wheel brushes, mounted, individual filament type,

16 Preparation for Welding – Surface Machining

Machining tasks: n Removing oxide skin n Cleaning n Removal of impurities without sig- nificant dimensional changes

Machinability group Wheel brushes ® SOFT POLIVLIES for angle Non-woven abrasive Files for soft Non-woven flap discs grinders belts metal abrasive rolls RBU INOX POLICLEAN® POLIVLIES®- PLUS® file discs hand pads

POLIVLIES® Manual Machinist’s hook and brushes for file - Cut 1 loop discs precision mechanics Flaring cup 15 – 60 HB brushes, Milled tooth threaded hole, file individual filament type Abrasive KBU INOX sheets

Machinability group Wheel brushes ® TOUGH POLIVLIES for angle Non-woven abrasive Files for soft Non-woven flap discs grinders belts metal abrasive rolls RBU INOX POLICLEAN® POLIVLIES®- PLUS® file discs hand pads

POLIVLIES® Manual Machinist’s hook and loop brushes for file - Cut 1 discs precision mechanics Flaring cup brushes, Milled tooth 40 – 150 HB threaded hole, file individual filament type Abrasive KBU INOX sheets

Machinability group Wheel brushes ® harD POLIVLIES for angle Non-woven abrasive Files for soft Non-woven flap discs grinders belts metal abrasive rolls RBU INOX POLICLEAN® POLIVLIES®- PLUS® file discs hand pads

POLIVLIES® Manual Machinist’s hook and brushes for file - Cut 1 loop discs precision mechanics Flaring cup brushes, Milled tooth 100 – 150 HB threaded hole, file individual filament type Abrasive KBU INOX sheets

17 Weld Dressing

Machining tasks: n Smoothing weld seams

n Removing defects n Cleaning n Levelling n Reworking repair welds

Machinability group Abrasive spiral Wheel brushes T/C burr with arbor hole, SOFT bands GSB Z-ALU individual filament Z-COOL, CO-COOL type, RBU INOX T/C burr COMBIDISC®- abrasive discs Pencil brushes, Z-ALU + mounted, knotted coating A-COOL, CO-COOL, SINGLETWIST® SiC PBGS INOX

HSS rotary ATADISC® Pencil brushes, cutter Z-ALU abrasive discs mounted, individual filament type,

15 – 60 HB PBU INOX + SiC Mounted points Grinding oils Hardness F-Alu 412 ALU

Wheel brushes, Mounted points mounted, individual Hardness L filament type, RBU INOX 0.30

Machinability group Wheel brushes, TOUGH T/C burr Mounted points mounted, individual Z-ALU Hardness L filament type, RBU INOX 0.30 T/C burr Abrasive spiral Wheel brushes with arbor hole, Z-ALU + bands GSB individual filament coating Z-COOL, CO-COOL type, RBU INOX COMBIDISC®- T/C burr abrasive discs Pencil brushes, Z-ALU PLUS mounted, knotted A-COOL, CO-COOL, SINGLETWIST® SiC PBGS INOX 40 – 150 HB HSS rotary ATADISC® Pencil brushes, cutter Z-ALU abrasive discs mounted, individual filament type, PBU INOX + SiC Mounted points Grinding oils Hardness F-Alu 412 ALU

Machinability group harD T/C burr Mounted points Ring wheels Z-ALU Hardness M A 24 M SG

T/C burr Abrasive spiral Wheel brushes, mounted, individual Z-ALU + bands GSB filament type, RBU coating Z-COOL, CO-COOL INOX 0.30

® Wheel brushes T/C burr COMBIDISC -abrasive with arbor hole, Z-ALU PLUS discs A-COOL, individual filament CO-COOL, SiC type, RBU INOX Pencil brushes, 100 – 150 HB T/C burr ATADISC® mounted, knotted SINGLETWIST® Z-3P abrasive discs PBGS INOX Pencil brushes, Mounted points Grinding oils mounted, individual Hardness F-Alu 412 ALU filament type, PBU INOX + SiC

18 Weld Dressing

Machining tasks: n Smoothing weld seams n Removing defects n Cleaning n Levelling n Reworking repair welds

Machinability group ® POLIVLIES flap Reinforced Short belts SOFT discs and hook grinding wheels A-COOL, Rasps and loop discs A 24 N SG-ALU CO-COOL Fibre discs POLIFAN® A-COOL, flap discs Files for soft metal CO-COOL SG-A-COOL Long belts Flaring cup brushes COMBICLICK® with threaded hole, ® A-COOL, PLUS file individual filament Grinding oils Machinist’s file - Cut 1 CO-COOL type, KBU INOX 412 ALU knotted, KBG INOX 15 – 60 HB Grinding oils Wheel brushes unmounted Milled tooth file 412 ALU knotted, RBG INOX POLICLEAN® Wheel brushes with Manual brushes disc arbor, female thread, for precision mechanics individual filament type, RBG INOX Machinability group POLIVLIES® flap Reinforced Short belts TOUGH discs and hook grinding wheels A-COOL, Files for soft metal and loop discs A 24 N SG-ALU CO-COOL Fibre discs POLIFAN® A-COOL, PLUS® file flap discs Long belts CO-COOL SG-A-COOL

® Flaring cup brushes COMBICLICK with threaded hole, A-COOL, individual filament Grinding oils Machinist’s file - Cut 1 CO-COOL type, KBU INOX 412 ALU knotted, KBG INOX

Grinding oils Wheel brushes, 40 – 150 HB unmounted Milled tooth file 412 ALU knotted, RBG INOX

® Wheel brushes POLICLEAN with arbor, female Manual brushes disc thread, individual for precision mechanics filament type, RBG INOX Machinability group POLIVLIES® flap Reinforced Short belts harD discs and hook grinding wheels A-COOL, Files for soft metal and loop discs A 24 N SG-ALU CO-COOL Fibre discs ® POLIFAN PLUS® file A-COOL, flap discs Long belts Machinist’s file - Cut 1 CO-COOL SG-A-COOL

® Flaring cup brushes COMBICLICK with threaded hole, A-COOL, individual filament Grinding oils Milled tooth file CO-COOL type, KBU INOX 412 ALU knotted, KBG INOX

Grinding oils Wheel brushes, 100 – 150 HB unmounted Diamond files 412 ALU knotted, RBG INOX

® Wheel brushes POLICLEAN with arbor, female Manual brushes disc thread, individual for precision mechanics filament type, RBG INOX

19 Fine Grinding and Finishing

Machining tasks: n Surface roughing / depolishing

n Levelling and removal or irregulari- ties n Removal of oxide skin n Secondary burr removal n Cleaning

Machinability group ® COMBIDISC POLINOX® SOFT POLICAP® abrasive discs mounted points A-COOL, CO-COOL PNZ/PNL SiC Non-woven discs POLINOX® POLIROLL®/ ATADISC®- abrasive wheels POLICO® abrasive discs PNZ/PNL/PNR/PNG/ PNER Fan grinders Wheel brushes, Z-COOL, SiC, Grinding oils mounted, individual CO-COOL 412 ALU filament type,

15 – 60 HB RBU SiC/INOX 0.15 Flap wheels Poliflex® fine-grind- Wheel brushes, INOX ing tools PUR/GR with arbor hole, individual filament type, RBU SiC

Machinability group POLINOX® ATADISC®- TOUGH POLICAP® abrasive wheels abrasive discs PNZ/PNL/PNR/PNG/ PNER POLIROLL®/ Grinding oils Wheel brushes, POLICO® 412 ALU mounted, individual filament type, RBU SiC/INOX 0.15 Fan grinders Poliflex® fine-grind- Z-COOL, SiC, Wheel brushes, ing tools PUR/GR CO-COOL with arbor hole, individual filament ® 40 – 150 HB type, RBU SiC Flap wheels POLINOX INOX mounted points PNZ/PNL SiC COMBIDISC® abrasive discs A-COOL, CO-COOL Non-woven discs

Machinability group Wheel brushes, ATADISC®- harD POLICAP® mounted, individual abrasive discs filament type, RBU SiC/INOX 0.15 POLIROLL®/ Grinding oils Wheel brushes, POLICO® 412 ALU with arbor hole, individual filament type, RBU SiC Fan grinders Poliflex® fine-grind- Z-COOL, SiC, ing tools PUR/GR CO-COOL

POLINOX® 100 – 150 HB Flap wheels mounted points INOX PNZ/PNL SiC COMBIDISC® POLINOX® abrasive discs abrasive wheels A-COOL, CO-COOL PNZ/PNL/PNR/PNG/ Non-woven discs PNER

20 Fine Grinding and Finishing

Machining tasks: n Surface roughing / depolishing n Levelling and removal or irregulari- ties n Removal of oxide skin n Secondary burr removal n Cleaning

Machinability group Manual POLIVLIES®- Car body POLIVLIES®- Short belts brushes for SOFT hook and files, special flap discs A-COOL, CO-COOL precision loop discs blade type mechanics Flaring cup INOX POLICLEAN®- Abrasive brushes, Long belts discs threaded hole, sheets individual Fibre discs filament type Abrasive A-COOL, KBU INOX Grinding oils 412 ALU band rolls CO-COOL

COMBICLICK® 15 – 60 HB Non-woven Non-woven A-COOL, abrasive belts abrasive rolls Z-COOL

Grinding oils POLIVLIES®- 412 ALU hand pads

Machinability group Manual POLIVLIES®- Car body POLIVLIES®- Short belts brushes for TOUGH hook and files, special flap discs A-COOL, CO-COOL precision loop discs blade type mechanics INOX POLICLEAN®- Abrasive Long belts discs sheets

Fibre discs Abrasive A-COOL, Grinding oils 412 ALU band rolls CO-COOL

COMBICLICK 40 – 150 HB Non-woven Non-woven A-COOL, abrasive belts abrasive rolls Z-COOL

Grinding oils POLIVLIES®- 412 ALU hand pads

Machinability group Manual POLIVLIES®- Car body POLIVLIES®- Short belts brushes for harD hook and files, special flap discs A-COOL, CO-COOL precision loop discs blade type mechanics INOX POLICLEAN®- Abrasive Long belts discs sheets

Fibre discs Abrasive A-COOL, Grinding oils 412 ALU band rolls CO-COOL

COMBICLICK® Non-woven Non-woven 100 – 150 HB A-COOL, abrasive belts abrasive rolls Z-COOL

Grinding oils POLIVLIES®- 412 ALU hand pads

21 Texturing

Machining tasks: n Creation of visual effects

n Achieving a homogeneous surface finish n Marbling n Matt finishing, directional brush or satin finishing n Removal of surface defects

Machinability group SOFT Marbling disc holder with non- Texturing tools woven disc PU-STRUC

Fan grinders Poliflex® marbling tools Z-COOL, SiC, CO-COOL

POLINOX® mounted points Flap wheels PNZ, PNL, PNR 15 – 60 HB POLINOX® abrasive wheels POLIFLAP® wheels PNZ, PNL, PNR, PNG, PNER

Grinding oils 412 ALU

Machinability group TOUGH Marbling disc holder with non- Texturing tools woven disc PU-STRUC

Fan grinders Poliflex® marbling tools Z-COOL, SiC, CO-COOL

POLINOX® mounted points Flap wheels PNZ, PNL, PNR

40 – 150 HB POLINOX® abrasive wheels POLIFLAP® wheels PNZ, PNL, PNR, PNG, PNER

Grinding oils 412 ALU

Machinability group harD Marbling disc holder with non- Texturing tools woven disc PU-STRUC

Fan grinders Poliflex® marbling tools Z-COOL, SiC, CO-COOL

POLINOX® mounted points Flap wheels PNZ, PNL, PNR

100 – 150 HB POLINOX® abrasive wheels POLIFLAP® wheels PNZ, PNL, PNR, PNG, PNER

Grinding oils 412 ALU

22 Texturing

Machining tasks: n Creation of visual effects n Achieving a homogeneous surface finish n Marbling n Matt finishing, directional brush or satin finishing n Removal of surface defects

Machinability group Short belts SOFT POLIVLIES® flap discs Abrasive sheets A-COOL, CO-COOL

POLIVLIES®- POLICLEAN® disc Long belts hand pads

POLIVLIES® non-woven discs Grinding oils 412 ALU Non-woven abrasive rolls 15 – 60 HB Non-woven belts

Machinability group Short belts TOUGH POLIVLIES® flap discs Abrasive sheets A-COOL, CO-COOL

POLIVLIES®- POLICLEAN® disc Long belts hand pads

POLIVLIES® non-woven discs Grinding oils 412 ALU Non-woven abrasive rolls 40 – 150 HB Non-woven belts

Machinability group Short belts harD POLIVLIES® flap discs Abrasive sheets A-COOL, CO-COOL

POLIVLIES®- POLICLEAN® disc Long belts hand pads

POLIVLIES® non-woven discs Grinding oils 412 ALU Non-woven abrasive rolls 100 – 150 HB Non-woven belts

23 Polishing

Machining tasks: n Polishing small surface areas

n High-gloss polishing

Machinability group SOFT Cloth rings Grinding compounds

Felt points

Felt wheels 15 – 60 HB COMBIDISC® felt discs

Polishing paste bars

Machinability group TOUGH Cloth rings Grinding compounds

Felt points

Felt wheels 40 – 150 HB COMBIDISC® felt discs

Polishing paste bars

Machinability group harD Cloth rings Grinding compounds

Felt points

Felt wheels 100 – 150 HB COMBIDISC® felt discs

Polishing paste bars

24 Tools for Use on Aluminium from PFERD Catalogues 201 - 209

Page Catalogue 201/201E Files and rasps 26

Catalogue 202 Burrs 27 – 28

Catalogue 203 Mounted points 29

Catalogue 204 Fine-grinding and polishing tools 30 – 31

Catalogue 205 Diamond and CBN tools 26

Catalogue 206 Grinding and cut-off wheels 32 – 34

Catalogue 208 Industrial power brushes 35

Catalogue 209 Tool drives 36

25 Files for Use on Aluminium Catalogues 201 and 205

PFERD files are suitable for deburring, chamfering, rough filing and smoothing work on aluminium and aluminium alloys. Tool loading problems are prevented by a tooth geometry adapted specifically to the requirements associated with working soft, sticky materials. As a result, minimum effort is needed to achieve a high-grade surface finish.

Machinability group SOFT Rasps Developed originally for woodworking applications, these tools also give excellent results on aluminium.

Machinability group SOFT, TOUGH and harD (hardness: 15 – 150 HB) Files for use on soft metals Particularly suitable for deburring, chamfering, roughing and smoothing work on soft, sticky materials.

PLUS® files For general use such as rough filing, smoothing and deburring.

Machinist’s files – Cut 1 Perfect for deburring.

Car body files (special blade type) For producing very good, scratch-free surfaces.

Milled tooth files These files ensure very high stock removal.

Machinability group harD Diamond files (Catalogue 205) Particularly well suited for deburring. Note

For further information refer to our PFERD Tool Manual, Catalogues 201 and 205. Products made to order Files Diamond and CBN Tools 201 205 Files can be manufactured to specific application needs by special arrangement.

Recommendations for use

Loaded files can be cleaned using our HBF 10 file brush.

26 Burrs and Rotary Cutters for Use on Aluminium Catalogue 202

Tungsten carbide burrs These tungsten carbide burrs give excellent results in aluminium work such as weld dressing, fettling of castings, deburring, chamfering and geometry adjustments. A large number of geometrical shapes and dimensions (3 - 16 mm dia.), two cuts and a coating developed specifically for this material are available to meet various needs in machinability groups SOFT, TOUGH and harD.

Our ALU and ALU PLUS cuts reflect the most recent standards of technology. Developed specifically for use on aluminium, their geometries ensure optimum machining results at high cutting rates of up to 1100 m/min.

T/C burrs with ALU cut T/C burrs with ALU PLUS cut T/C burrs with HC-NFE coating ALU cut

Vc 600-1100 m/min Vc 450-700 m/min Vc 600-1100 m/min

An optimum tooth geometry ensures good Preferable for coarse milling of aluminium The tool of choice for long-chip, sticky nonferrous metals in machinability groups chip removal. Tooth base loading is prevented, alloys in machinability groups TOUGH and SOFT, TOUGH and harD. Improved even on sticky materials. For use in machina- harD, as well as for non-ferrous metals in friction and sliding properties reduce the for- bility groups SOFT, TOUGH and harD. general. The special tooth geometry ensures mation of built-up edges. High stock removal high stock removal. and durability are the hallmarks of this range.

HSS rotary cutters Thanks to their special tooth geometry and close tolerances, ultrahigh-speed steel (HSS) rotary cutters are particularly suitable for deburring, chamfering, fettling and geometry adjustment work on aluminium parts, where they produce an enhanced surface quality. HSS rotary cutters with ALU cut can be used in numerous shapes and dimensions.

HSS rotary cutters with ALU cut and with our special cut for light alloys guarantee cost-efficient results and are also ideal for use on machinability group SOFT and TOUGH materials when working with a low-powered machine in the low r.p.m. range.

HSS rotary cutter with ALU cut HSS rotary cutter with special cut for Products made to order light alloys If our extensive Catalogue range should not include what you need, we can produce custom products tailored Vc = 300 m/min Vc = 300 m/min to your requirements in terms of An optimum tooth geometry ensures good Particularly suitable for coarse deburring and chip removal. fettling work on light alloy components and n tooth specifications castings. n shank length n diameter. Recommendation for use Especially in high-volume manufactur- n The cost-efficiency of burrs and rotary cutters is contingent on an adequate ing, milling operations are increasingly power output and appropriate r.p.m. of the machine. robotized. For such applications PFERD To select the right cut for a given application, note the following rule: offers burrs and rotary cutters provid- The harder and more brittle the material, the finer the cut should be . ing still closer tolerances and constant n The coating of tungsten carbide burrs prevents tool loading problems under stock removal. most application conditions, even with very sticky alloys. With uncoated burrs, Please do not hesitate to contact us. grinding oil can be used to prevent tooth bases from clogging up too quickly. The application technicians in our technical customer support department will be glad to help.

27 Hole Saws and Hole Cutters for Use on Aluminium Catalogue 202

HSS hole saws

HSS hole saws are excellent for producing fast and accurate cutouts. Their high- grade HSS teeth set guarantees cost-efficient performance, particularly on thin- walled aluminium components in the SOFT and HARD machinability group. A long service life and burr-free edges are achieved with these tools.

HSS hole saw sets

PFERD offers five different sets of hole saws in the most common diameters used by craftsmen, plumbers, fitters and electricians (Germany and interna- tional).

Carbide-tipped hole cutters

Thanks to their high-grade hard metal tips, these carbide hole cutters provide outstanding results and superior cost-efficiency on aluminium alloys in the harD machinability group. Two versions (flat, deep) facilitate machining on diverse workpieces, including curved surfaces.

8 mm Carbide-tipped hole cutters are supplied in two heights: n 8-mm (flat) version for use on sheet metal and flat material, available in various diameters from 16 to 105 mm. n 35 mm (deep) version for use on pipes and curved surfaces, available in various diameters from 16 to 60 mm.

35 mm

Note Burrs 202 Recommendations for use For further informa- n To reduce cutting forces, paraffin should be used when sawing aluminium. tion refer to our This will ensure a smoother operation of the tool while also extending its PFERD Tool Manual, service life. Catalogue 202.

28 Mounted Points for Use on Aluminium Catalogue 203

Mounted points are suitable for pre-grinding, deburring, chamfering, fettling and fine-grinding aluminium and associated alloys in theSOFT , TOUGH and harD machinability groups. Since the space between grit particles (chip clearance) is very small on these tools, they are particularly susceptible to loading. PFERD has therefore developed a special bond which ensures unsurpassed stock removal over the entire tool life even on soft, sticky materials.

Mounted points – hardness F-Alu

These tools are made with a vitrified bond and green silicon carbide. A special treatment prevents loading on sticky materials. The hardness F-Alu denotes one of the softer and most aggressive bonds available for mounted points. Hardness F-Alu

Products made to order

By special arrangement we can produce mounted points adapted specifically to your application needs, e.g., n other dimensions and shapes n different grit sizes and abrasive types n bespoke grain mixtures Hardness M n special shank diameters and lengths.

In addition, PFERD supplies impregnated special product versions in hardness grades M and L for use on aluminium. These tools are specially designed to prevent loading on particularly sticky aluminium materials (machinability group SOFT). Hardness L

Recommendations for use n Mounted points of hardness grade F-Alu perform best at a recommended peripheral speed of 20 - 40 m/s. n The use of grease or grinding oil is recommended. n Mounted points are used with flexible shafts or (electric or air-powered) straight grinders.

Safety notes n All mounted points in the PFERD range are approved for a maximum peripheral speed of 50 m/s. Applicable r.p.m. limits for the various shank lengths and shank diameters are defined in EN 12413. It is absolutely necessary to comply with these maximum values to prevent the tool shank from buckling in use.

Mounted Points Note Mounted Points 203 For further information refer to our 203 PFERD Tool Manual, Catalogue 203.

203 I 1

29 Grinding and Polishing Tools for Use on Aluminium Catalogue 204

Fine-grinding and polishing tools are suitable for pre-grinding, deburring, chamfering, fettling, fine-grinding, texturing and polishing operations on aluminium and its alloys in hardness grades SOFT, TOUGH and harD. The specific aluminium machining tools can be summarized in groups: n Coated abrasive tools n Non-woven abrasive tools n Bonded abrasive tools n Polishing tools

Coated abrasive tools Coated abrasive tools in Catalogue 204: Coated abrasive tools, with a cover bond actively supporting the grinding process, are suitable for use on aluminium surfaces. The additional cover layer cools the n Abrasive spiral bands workpiece and prevents aluminium from adhering to the spaces between abra- n POLIROLL®, POLICO® sive particles. Silicon carbide (SiC) is highly suitable for use on aluminium due to the shape of its grains. Depending on grit size, coated abrasive tools can provide n Fan grinders, flap wheels high removal rates (e.g., during chamfering with 36 grit fibre discs) or a very fine and flap rolls surface finish if a fine-grained abrasive is used (e.g, pre-polishing with a 320 grit n COMBIDISC® and ATADISC®- grind- fan grinder). ing discs The service life of coated abrasive tools can be greatly extended through the use n Special tools of our grinding oil 412 ALU. This oil prevents chip particles from adhering to the n Short and long belts abrasive surface and thereby prevents loading problems. n Economy rolls and sheet material Active abrasion- Structure of coated abrasive n Fibre discs and promoting layer products hook-and-loop discs n COMBICLICK® fibre discs n Grinding oil 412 ALU

Backing Basic Cover Abrasive material bond bond grain

Non-woven abrasive tools Non-woven abrasive tools in Catalogue 204: The very open structure of the non-woven abrasive material prevents loading and heat build-up during grinding. Non-woven abrasive tools are excellent for ® ® n COMBIDISC and ATADISC - producing fine and ultra-fine finishes, removing oxide layers, and creating surface non-woven discs textures. n POLINOX® mounted points, wheels and drums Structure of Synthetic Abrasive fibre non-woven grain n Special tools abrasive n POLIVLIES® Special tools Resin n POLIVLIES® hook-and-loop discs n POLICLEAN® tools n Short belts, non-woven types

30 Grinding and Polishing Tools for Use on Aluminium Catalogue 204

Recommendation for use: n In aluminium machining applications, coated abrasive tools perform best at the recommended peripheral speed of 20 – 40 m/s. n Non-woven abrasive tools give best results on aluminium when used at the recommended peripheral speed of 10 – 20 m/s. n Polishing operations should be carried out at peripheral speeds of 5 – 10 m/s. n The use of a grinding oil is recommended as it protects the tool from premature wear. n Suitable power sources are flexible shaft drives or (electric or air- powered) straight grinders.

Bonded abrasive tools Bonded abrasive tools Bonded abrasive tools give outstand- in Catalogue 204: ing performance in fine grinding and ® pre-polishing jobs, e.g., on aluminium n Poliflex mounted points moulds for plastic injection moulding n Poliflex® abrasive discs (blow moulding of PET bottles). Fine- n ® grinding tools adapted to each applica- Poliflex blocks tion are available in the most diverse shapes and a broad range of grit types, grit sizes and hardness grades.

Polishing tools Polishing tools PFERD offers an extensive range of in Catalogue 204: aluminium polishing tools in diverse n Felt points and discs diameters, hardness grades, grit sizes, types and shapes, as well as the associ- n Cloth rings ated polishing pastes / compounds. n Grinding compounds n Polishing pastes

Products made to order

If our extensive Catalogue range should not include what you need, we can produce bespoke solutions for your application needs, e.g., Notes n other dimensions and shapes All PFERD tools are n different grit sizes and abrasive types manufactured and Fine Grinding and Polishing Tools tested to applicable 204 n bespoke grain mixtures safety standards. n special shank diameters and lengths. For further informa- Please talk to your sales advisor. The application technicians in our technical cus- tion refer to our tomer support department will be glad to help. PFERD Tool Manual, Catalogue 204.

31 Abrasive Cut-Off Wheels for Use on Aluminium Catalogue 206

For cutting aluminium and its alloys, PFERD has developed a range of special abrasive cut-off wheels. These products contain no fillers which might leave undesirable residue on the workpiece. The surfaces can therefore be welded immediately afterwards.

Abrasive cut-off wheels - hardness N-Alu

Abrasive wheels of hardness grade N-Alu provide aggressive stock removal and are not susceptible to loading problems on aluminium workpieces in machinability groups SOFT, TOUGH and harD. They are laminated on both sides with a silver-coated labelling film which prevents metal adhesion and clogging of the abrasive material.

Products made to order

By special arrangement, abrasive cut-off wheels for use on aluminium can be manufactured to specific application needs.

Special specifications may include, e.g., n non-standard sizes and widths n different grit types, e.g., SiC

Recommendations for use: n 1.0 mm disc width: especially for sheet metal n 1.6 mm disc width: for thin-walled workpieces n 2.4 mm disc width: for general cut-off work n 2.9 mm disc width: for maximum tool life and high lateral stability

Safety notes

Abrasive manufacturers, machine producers and users contribute equally to ensur- ing grinding safety. All PFERD tools are built to meet applicable safety requirements. However, the ultimate responsibility for the correct handling and safe operation of power tools and abrasive products rests with the user.

In particular, the following rules apply: n The maximum operating speed (m/s) stated on the product label must not be exceeded. n The use of flanges having two different diameters is to be avoided.

32 Reinforced Grinding Wheels or Use on Aluminium Catalogue 206

For grinding work on aluminium and aluminium alloys, PFERD has developed special reinforced grinding wheels which provide high stock removal and will not load even when used on soft material types.

Reinforced grinding wheels - hardness N-Alu

These tools deliver outstanding stock removal even at low contact pressure, thus effectively preventing loading problems on alloys in machinability groups SOFT and TOUGH. Reinforced grinding wheels made by PFERD are suitable for use with angle grinders of all output categories. They contain no fillers which might leave undesirable residue on the workpiece. Machined surfaces can therefore be welded right away.

Reinforced grinding wheels - hardness O-Alu

Suitable for alloys in machinability groups TOUGH and harD.

Products made to order

Reinforced grinding wheels for use on aluminium can be manufactured to your specific application needs by special arrangement.

Special specifications may include, e.g., n non-standard sizes and widths n different grit types, e.g., SiC

Recommendations for use n 7.2 mm disc width: suitable for general-purpose grinding.

Safety notes n The maximum operating speed (m/s) stated on the product label must not be exceeded. n In some countries, 178/230 mm dia. reinforced grinding wheels are subject to special regulations regarding the use of special flanges and/or adapter systems.

33 POLIFAN® Flap Discs for Use on Aluminium Catalogue 206

For use on aluminium, POLIFAN® flap discs with an abrasion-promoting coating covering the grit on each flap are particularly suitable. This feature prevents aluminium chips from adhering to the abrasive material.

The service life of coated abrasive products can be extended significantly through the use of our grinding oil 412 ALU. Adding this oil will help avoid tool loading and the adhesion of chip particles.

POLIFAN® flap discs - SG-A-COOL Designed for outstanding metal removal rates and low heat build-up when used on variable-speed angle grinders, these tools are ideal for work on sheet metal and light-gauge sections in machinability groups SOFT and TOUGH.

POLIFAN® flap discs - SG-A Suitable for general-purpose grinding on weld seams and edges in machinability group TOUGH and harD materials.

POLIFAN® flap discs - SGP-CO-COOL These special purpose tools meet the most exacting grinding standards, delivering cool grinding performance, aggressive stock removal at minimum contact pressure, plus outstanding cost-efficiency. They are suitable for workpieces in machinability groups TOUGH and harD.

Products made to order Upon request, POLIFAN® flap discs can be produced to your specific application requirements. Custom specifications may include, e.g., n non-standard dimensions n different grit types, e.g., SiC

Recommendations for use n Recommended for use in all three machinability groups. n Designed preferably for use in the lower r.p.m. range of variable-speed angle Notes grinders. All PFERD tools are manufactured and n The use of grinding oil is recommended as a safeguard against premature tested to applicable Grinding and Cut-Off Wheels wear. 206 safety standards.

Safety note For further informa- n The maximum operating speed (m/s) stated on the product label must not be tion refer to our exceeded. PFERD Tool Manual, Catalogue 206.

34 Industrial Power Brushes for Use on Aluminium Catalogue 208

The flexibility benefits of industrial power brushes become particularly evident when it comes to machining aluminium. A brush can deburr workpieces and condition surfaces without significantly interfering with the material’s dimensional accuracy. This holds true both on handheld machines and in stationary or robotized use. Industrial power brushes for use on aluminium are particularly well suited for fine deburring work on machinability group SOFT, TOUGH and harD materials.

SiC fill brushes Abrasive grit is encapsulated in the flexible nylon filaments. New grit becomes progressively exposed as the carrier material wears down so that the brush retains its constant aggressiveness. Available in different grit sizes for diverse applications.

INOX fill brushes These brushes are suitable for removing the oxide skin from aluminium surfaces, e.g., in preparation of welding. All INOX brushes made by PFERD are supplied in a SiC degreased state and will therefore not leave any corrosive residue or foreign matter on the workpiece.

INOX

Products made to order Industrial power brushes Schematic view in Catalogue 208: If our extensive Catalogue range SiC fill should not include what you need, we n Wheel brushes with arbor hole can customize products to your appli- n Mounted wheel brushes cation in terms of filament gauge, grit Abrasive grit is n Cup brushes with threaded hole size, diameter, and fill width/length. encapsulated in nylon filaments. n Disc brushes Fresh grit gets Please talk to your sales advisor or n Mounted cup brushes progressively contact the application technicians in exposed. n Mounted pencil brushes our technical customer support depart- n Interior brushes with threaded hole ment. They will be glad to help! n Scratch brushes

Recommendations for use n To avoid corrosion, do not work with brushes previously used on steel, copper or other metals. n For “fine” deburring work on complex components, use an SiC-filled brush. n The use of SiC-filled brushes with longer filaments is recommended for deburring complex aluminium parts. n An INOX brush should be preferred for “heavy” burr removal. Notes n INOX brushes used on aluminium should have the smallest filament diameter All PFERD tools are manufactured and consistent with application. tested to applicable Accessories Industrial Power Brushes n On applications which place particular demands on high brush aggressiveness, safety standards. 208 disc brushes with rectangular SiC fillings (REC) should be used. n The above-mentioned PFERD brushes will give best results on aluminium when

used at the following recommended cutting speeds: For further informa- Platzhalter - Wheel brushes (including flaring cup brushes) with SiC fill: 10 – 20 m/s tion refer to our für Titel - Wheel brushes (including flaring cup brushes) with INOX fill: 15 – 30 m/s PFERD Tool Manual, - Pencil brushes 5 – 10 m/s Catalogue 208. 208 - Cup brushes 25 – 35 m/s 208 I 1 - Disc brushes 10 – 20 m/s

35 PFERD Power Tools for use on Aluminium Catalogue 209

PFERD offers an extensive machine range adapted to the performance, r.p.m. and power specifications of PFERD tools. These machines are engineered to optimize the cost-efficiency of our products and comply with the applicable version of the EC Machinery Directive 2006/42/EC.

Light finishing, grinding, polishing and deburring work requires less power output but a more handy machine. On the other hand, normal milling, grinding, coarse machining and deburring jobs (especially under heavy-duty conditions) call for the use of powerful and rugged machines. Printed in Germany.

Air grinders Electric grinders Flexible shafts and drive units Turbine-type, straight, angle and belt Straight, angle, drum and belt Flexible shaft drives powered by grinders grinders universal or three-phase motors. Speed range: Speed range: Speed range: 3,000 – 100,000 r.p.m. 750 – 33,000 r.p.m.1 0 – 36,000 r.p.m. Power rating: Power rating: Power rating:

75 – 1,000 W 500 – 1,530 W 500 – 2,400 W Subject technical to modifications.

Recommendations for use Recommendations for use Recommendations for use

n Particularly suitable, given that air n Use only with a very effective ex- n Mount the drive motor outside motors produce no sparks. traction system, e.g., with a wet the grinding booth or dust

n Preferable for tools requiring separator. The sparks produced emission site. 09/2008 speeds over 36,000 r.p.m. by the carbon brushes may ignite n Virtually all PFERD tools described aluminium dust. n For tools which can only be used in this publication can be used. in one r.p.m. range. n Electric machines should be cleaned with compressed air after use. 817 117 817

Workplace design recommendations Safety note Select machines in accordance with n The ideal workplace for machining aluminium workpieces is equipped with the classification of your workplace as an effective extraction system and, possibly, wet extraction equipment. defined in BGR 109, “Prevention of Dust The explosion or fire hazard resulting from spark formation increases with Fires and Dust Explosions during Alumin- the concentration of aluminium particles in the air. Special caution must be ium Grinding, Brushing and Polishing”, a exercised when working aluminium materials which contain magnesium; publication of the German Association of their dusts may be highly explosive. Spark-producing power units constitute a Workmen’s Compen- Tool Drives Tool Drives hazard. However, sparks may also result from tool-to-material contact. sation Insurers. 209 n Classify work environments according to the codes of the Workmen’s Note Compensation Insurance Association with regard to the prevention of dust For more detailed fires and dust explosions, then select power units in accordance with this information on power Platzhalter für Titel classification. tools and motor units for tool drives, please

refer to our Tool Man- 209 ual, Catalogue 209. 209 I 1

36 www .pferd com. · info@pferd .com